Vacuum cleaner

ABSTRACT

A vacuum including a suction inlet and a suction source. The vacuum also includes a dirt cup in fluid communication with the suction inlet and the suction source. The dirt cup includes a first stage cyclonic separator and a dirt collection chamber. A housing of the dirt cup includes a first end, a second end, and a neck region between the first end and the second end. The housing has an outer dimension that decreases in a direction from the first end toward the neck region and an outer dimension that decreases in a direction from the second end toward the neck region. The dirt cup includes a shroud within the housing, and the shroud includes a flange that divides the housing at the neck region. The dirt collection chamber and at least a portion of the shroud are between the second end of the housing and the flange.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 62/528,815, filed Jul. 5, 2017, the entire contents of which are hereby incorporated by reference herein.

BACKGROUND

The present invention relates to vacuum cleaners, particularly cyclonic vacuum cleaners.

SUMMARY

In one embodiment, a vacuum includes a suction inlet and a suction source in fluid communication with the suction inlet. The suction source includes a motor and a fan. The vacuum also includes a dirt cup in fluid communication with the suction inlet and the suction source. The dirt cup includes a first stage cyclonic separator and a dirt collection chamber. A housing of the dirt cup includes a first end, a second end, and a neck region between the first end and the second end. The housing has an outer dimension that decreases in a direction from the first end toward the neck region and an outer dimension that decreases in a direction from the second end toward the neck region. The dirt cup includes a shroud within the housing, and the shroud includes a flange that divides the housing at the neck region. The dirt collection chamber and at least a portion of the shroud are between the second end of the housing and the flange.

Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a vacuum cleaner including a dirt cup and a shroud according to one embodiment.

FIG. 2 is an enlarged side view of the vacuum cleaner of FIG. 1.

FIG. 3 is a cross-sectional view of the vacuum cleaner along 3-3 in FIG. 1.

FIG. 4 is a side view of the dirt cup of FIG. 1.

FIG. 5 is another side view of the dirt cup of FIG. 1.

FIG. 6 is a view from a first end of the dirt cup of FIG. 1.

FIG. 7 is a view from a second end of the dirt cup of FIG. 1.

FIG. 8 is a side view of the shroud of FIG. 1.

FIG. 9 is a side view of a cyclone that is positioned within the shroud of FIG. 1.

FIG. 10 is a view of a first end of the cyclone of FIG. 9.

FIG. 11 is a cross-sectional view of the cyclone of FIG. 9 along 11-11 of FIG. 9.

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.

FIG. 1 illustrates a vacuum cleaner 10. The illustrated vacuum cleaner 10 includes a handle 12, a base 14, a suction source 16, and a dirt cup 18. The handle 12 is pivotally coupled o the base 14 and the handle 12 includes a support structure 20 extending in a generally vertical orientation or upwardly from the base 14. The base 14 includes a suction nozzle 22 and wheels 24 that facilitate movement of the base 14 along a surface being cleaned. The suction source 16 includes a clean air exhaust 26. Although the illustrated embodiment is an upright vacuum cleaner, alternative embodiments may include canister vacuum cleaners, stick vacuum cleaners, handheld vacuum cleaners, etc.

As shown in FIGS. 1-2 and 4-7, the dirt cup 18 includes a housing 30 that has a first or upper end 34, a second or lower end 38, and a neck region 42 between the first end 34 and the second end 38. The housing 30 defines a longitudinal axis A, and the housing 30 has a variable outer dimension D₁. In the illustrated embodiment, the outer dimension D₁ is the diameter of the housing 30 because the cross-section of the housing 30 is substantially circular. In alternative embodiments, the cross-section of the housing 30 may have other shapes and corresponding outer dimensions (e.g., the cross-sections could be oval, elliptical, or any other suitable shape). In the illustrated embodiment, the outer dimension D₁ (FIG. 4) decreases in a direction from the upper end 34 toward the neck region 42 and decreases in a direction from the lower end 38 toward the neck region 42. The neck region 42 defines the outer dimension of the housing 30 that is the smallest. Accordingly, the housing 30 of the dirt cup 18 has an hourglass shape. The dirt cup 18 includes a dirty air inlet 46 that is substantially tangential to a perimeter of the housing 30 and positioned between the lower end 38 and the neck portion 42. In particular, the dirty air inlet 46 has a wall 50 that is substantially tangential to the perimeter of the housing 30. The dirty air inlet 46 is in fluid communication with the suction nozzle 22 via a conduit 54 (FIGS. 1 and 2). Further, the dirt cup 18 includes an air outlet 196 that extends through an aperture 58 of the housing 30 and is positioned between the upper end 38 and the neck portion 42. The dirt cup 18 may include a handle 62 coupled to the housing 30, while a lid 66 is moveably (i.e., hingeably) coupled to the lower end 38 of the housing 30. Optionally, the lid 66 may include one or more ribs or projections 70 that are positioned within the housing 30 when the lid 66 is in a closed position (FIGS. 1 and 2).

FIGS. 1 and 2 illustrate a shroud 100 that is positioned in the housing 30 including a plurality of apertures 104 forming an air passageway. The shroud 100 includes a flange 108 positioned adjacent the neck portion 42 separating the housing 30 into an upper portion 112 and a lower portion 116. The neck portion 42 is positioned such that at least a portion of the shroud 100 is between the second end 38 of the housing and the flange 108. The shroud 100 may have a shape that is cylindrical, tapered, or may have other shapes and corresponding outer dimensions. The plurality of apertures 104 may be holes formed in the shroud 100, or may be formed by openings through a screen or mesh. The shroud 100 may include one or more areas 124 that are free of apertures. A skirt 128 may be coupled to the shroud 100. Optionally, one or more ribs or projections 132 may be provided adjacent the skirt.

With respect to FIGS. 3 and 8, the flange 108 has a seal 140 that seals against the housing 30 at the neck region 42 inhibiting air flow along the wall of the housing 30 between the upper portion 112 and the lower portion 116. In the illustrated embodiment, the seal 140 is positioned between a first member 144 and a second member 148 of the flange 108.

Further with respect to FIG. 3, he lower portion 116 between the lower end 38 of the housing 30 and the flange 108 includes a first stage cyclonic separator 152 and a dirt collection chamber 156. As shown in FIGS. 1 and 2, at least a portion of the shroud 100 is positioned within the first stage cyclonic separator 152. Further, the dirty air inlet 46 of the housing 30 allows communication between the first stage cyclonic separator 152 and the suction nozzle 22, and is positioned adjacent the area 124 free of apertures.

In the illustrated embodiment, a second stage separator assembly 160 is provided within the shroud 100, wherein at least a portion of the second stage separator assembly 160 is between the first end 34 of the housing and the flange 108. The second stage separator assembly 160 includes an inner housing 168 having a first or upper end 172 and a second or lower end 176. One or more second stage cyclones 184 are positioned within the inner housing 168, and each cyclone 184 defines a perimeter and a longitudinal axis B (FIG. 3). Each of the second stage cyclones 184 includes one or more outlets 186 generally along axis B towards the upper end 172. Each of the second stage cyclones 184 includes one or more inlets 180 substantially tangential to the perimeter of the corresponding cyclone 184. In particular, each inlet 180 has a wall 188 that is substantially tangential to the perimeter of the corresponding cyclone 184. An intermediate housing 190 is connected to the shroud 100 bounding an air passageway along the inner housing 168 between the shroud apertures 104 and the cyclone inlets 180.

A tube 192 forming a dust collection chamber is coupled to the inner housing 168 and extends between the lower end 176 of the inner housing 168 and the lower end 38 of the housing 30. The cyclone outlets 186 are in communication with a dirt cup outlet 196 providing fluid communication between the shroud 100 and the suction source 16 through an outlet duct (not shown) in or adjacent to the support structure 20.

In the illustrated embodiment, there are five cyclones 184 (FIG. 10). In other or additional embodiments there may be a fewer or greater number of cyclones. In one embodiment, the second stage separator assembly 160 includes one second stage cyclone 184 where at least a portion of the inner housing 168 forms a portion of the cyclone.

The intermediate housing 190 may be connected to the shroud 100 and/or the flange 108. In the illustrated embodiment, the intermediate housing 190 is integral with the shroud 100 and flange the 108. At least a portion of the intermediate housing 190 may be integrally formed with the shroud 100. In the illustrative embodiment, the intermediate housing 190 forms a decorative panel 200 in at least a portion of the upper portion 112, visible through the housing 30 between the first end 34 and the flange 108 when the housing 30 includes a transparent or translucent material. The seal 140 sealing against the housing 30 at the neck region 42 inhibits dust from the first stage cyclone 144 flowing along the wall of the housing 30 and contacting the decorative panel 200.

Optionally, the air passageway between the shroud 100 and the suction source 16 includes a filter (not shown). In the illustrated embodiment the filter is positioned adjacent the suction source 16. Alternatively, the filter may be provided within the inner housing 168 adjacent the upper end 172 between the cyclone outlets 186 and the dirt cup outlet 196.

In an alternative embodiment, the second stage separator assembly 160 is omitted and the dirt cup includes a single stage separator. In this embodiment, a filter may be provided within the intermediate housing between the shroud 100 and the dirt cup outlet 196. Alternatively, the filter may be provided adjacent the suction source 16.

In operation, referring to FIG. 1, the suction source 16 generates an airflow that draws debris and the airflow through the suction nozzle 22. The airflow and entrained debris travel through the conduit 54 (FIGS. 1 and 2) to the dirty air inlet 46 of the housing 30. In particular, the airflow and entrained debris are guided into the first stage cyclonic separator 152. The airflow and debris are rotated about the longitudinal axis A of the housing 30 between the flange 108 and the skirt 128, which causes the debris to separate from the airflow. The debris falls into the dirt collection chamber 156 (i.e., to the lower end 38 of the dirt cup 18), while the airflow moves into the shroud 100 through the apertures 104. The airflow and any remaining entrained debris travel into the second stage cyclones 184. More specifically, the airflow and any remaining entrained debris travel into the inlets 180 of the cyclones 184. The airflow and debris are rotated about the longitudinal axis B of the corresponding cyclones 184, which causes any remaining debris to separate from the airflow. The debris is falls into the dust collection chamber tube 192, which guides it to the lower end 38 of the dirt cup 18. The clean airflow then travels through the cyclone outlets 186 and through the outlet 196. The clean airflow then travels through the outlet duct in or adjacent to the support structure 20 to the suction source 16 before being discharged from the vacuum cleaner 10 through the clean air exhaust 26.

The embodiment shown and described herein the vacuum is a multi-stage cyclonic separator. In alternative embodiments, the vacuum could be a single-stage cyclonic separator. Various features and advantages of the invention are set forth in the following claims. 

1. A vacuum comprising: a suction inlet; a suction source in fluid communication with the suction inlet, the suction source including a motor and a fan; a dirt cup in fluid communication with the suction inlet and the suction source, the dirt cup including a first stage cyclonic separator, a dirt collection chamber, a housing having a first end, a second end, and a neck region between the first end and the second end, the housing having an outer dimension that decreases in a direction from the first end toward the neck region and an outer dimension that decreases in a direction from the second end toward the neck region, a shroud within the housing, the shroud including a flange dividing the housing at the neck region, wherein the dirt collection chamber and at least a portion of the shroud are between the second end of the housing and the flange, wherein the flange inhibits air flow along the housing at the neck region between the first end and the second end.
 2. The vacuum of claim 1, wherein the housing forms an hourglass shape.
 3. The vacuum of claim 1, wherein the housing is transparent or translucent, and the dirt cup further comprising a decorative panel visible through the housing between the first end and the flange.
 4. The vacuum of claim 1, further comprising a second stage cyclonic separator, wherein at least a portion of the second stage cyclonic separator is between the first end of the housing and the flange.
 5. The vacuum of claim 4, the second stage cyclonic separator further comprising one or more cyclones, each cyclone defining a perimeter and having an inlet being substantially tangential to the perimeter of the corresponding cyclone.
 6. The vacuum of claim 1, wherein the shroud is positioned in the first stage cyclonic separator and includes a plurality of apertures.
 7. The vacuum of claim 9, wherein the flange includes a seal that seals against the housing at the neck region.
 8. The vacuum of claim 7, wherein the flange includes a first flange member and a second flange member, the seal positioned between the first flange member and the second flange member.
 9. The vacuum of claim 1, wherein the flange seals against the housing at the neck region.
 10. The vacuum of claim 1, wherein the housing includes an upper portion disposed between the first end and the flange and a lower portion disposed between the second end and the flange, wherein the flange inhibits air flow along the housing at the neck region between the upper portion and the lower portion. 